KR100332727B1 - Method and apparatus for forming composite strands - Google Patents

Abstract

The method and apparatus 10 of the present invention for the production of synthetic strands 16 is provided. The apparatus 10 includes a heating bushing 12 for supplying a stream of molten glass to be drawn out into a continuous first fiber 14, and a drawer 20 suitable for drawing the stream into the first fiber 14; Supply facilities for supplying one or more second fibers 66 of the second material, one or more applicators 30, 35 for applying the size to the first and second fibers 14, 66, and the first and the first An apparatus 50 for gathering two fibers 14, 66 into one or more synthetic strands 16.

Description

Synthetic strand forming method and apparatus {METHOD AND APPARATUS FOR FORMING COMPOSITE STRANDS}

There are several methods for producing synthetic strands containing glass and organic materials. Methods such as solution treatment, slurry treatment, and impregnation include passing the fiberglass tow through a polymer containing liquid. The polymer sticks to the tow to produce a composite. Another known method, such as film stacking, requires stacking fiber toes between sheets of thermoplastic and applying pressure for an extended time. Another method, called dry powder injection, involves adding thermoplastic powder to the fiber tow to heat the powder particles to sinter the fibers.

The above described methods all have several disadvantages. A common disadvantage of all methods is the fact that one or more off-line glass tow spreading treatment steps are required to produce the final synthetic strand product. This off-line step increases the cost of the product and the complexity of the production process.

The fiber mixture can be carried out using an in-line method, which is another method of producing synthetic strands. Methods such as those disclosed in U.S. Patent No. 5,011,523 feed molten glass to the bushings, withdraw the glass fibers from the bushings, and apply the size to the fibers through an applicator roller. Sized fibers are collected in one or more yarns and combined with the polymer fibers. The mass of fibers thus produced is collected in a single tow of the assembly apparatus, and then wound around a collet, respectively, to produce a synthetic strand package or immediately cut into pieces.

Despite being an in-line process, the same method as described above has several disadvantages. In particular, the problem of setting up polymers in processed strands is of interest. In particular, the strand of the synthetic material produced does not disperse the thermoplastic material in the product cross-sectional area. In addition, the polymer only wraps the glass fibers. In addition, the amount of binder / size in the final product is very small (about 0.5%). Thus, the synthetic materials formed in these products do not distribute the polymer over its cross-sectional area so that the fibers do not bond strongly to each other.

Accordingly, there is a need to provide an improved method for forming synthetic strands that produces a relatively high binder / size in synthetic strand products by dispersing the thermoplastic fibers with our fibers in relation to the synthetic strand cross-sectional area. There is also a need to provide an improved method of forming synthetic strand products to be produced in a more effective and economical way.

Initiation of the invention

In accordance with the present invention, the above needs are met so that one or more synthetic strands are formed in an improved in-line method. The method has the advantage of providing a synthetic strand comprising the separated first and second fibers, while allowing the second fibers to intersect over the strand cross-sectional area.

According to a first aspect of the invention, an apparatus for producing one or more synthetic strands is provided. The apparatus comprises a heating bushing for supplying a flow of molten glass to be drawn towards a continuous first fiber, a drawer suitable for drawing the flow towards the first fiber, and a feed for supplying one or more second fibers of a second material An apparatus, one or more applicators for applying a size to the first and second fibers, and an apparatus for gathering the first and second fibers into one or more synthetic strands.

The apparatus includes a drying apparatus for contacting and delivering thermal energy to the first and second sized fibers to dry the size on the first and second fibers prior to gathering the first and second fibers on one or more strands. It includes more. The drying apparatus preferably includes a heating contact plate.

In addition, the gathering apparatus of the apparatus preferably includes a gathering shoe located between the drying apparatus and the take-out apparatus for gathering the first and second fibers into one or more synthetic fibers. The take out device may include a winding device. Optionally, the take out device may comprise an in-line chopping device. Optionally, a single applicator can be used to apply the size to the first and second fibers. The first applicator can be used to apply the size to the first fiber and the second applicator can be used to apply the size to the second fiber. Moreover, it is designed so that a size can be apply | coated to any one of a 1st and 2nd particle | grains by a single applicator. According to a second aspect of the invention, a method of forming one or more synthetic strands is provided. The method includes drawing a plurality of glass first fibers from a molten glass source, providing a supply of one or more second fibers of a second material, and applying a size to the first and second fibers. And collecting the first and second fibers into one or more composite strands. The second fiber is preferably selected from the group consisting of S-grass fibers, graphite fibers, and polymer fibers. The second fiber is preferably selected from the group consisting of polyamide fibers, polypropylene fibers and polypropylene sulfide fibers.

The method further comprises contacting the sized first and second fibers with a heating element to dry the size on the first and second fibers. The heating element evaporates at least part of the water in the size of the aqueous base. In addition, the size may comprise a film former consisting of an acrylic polymer emulsion or urethane.

According to a third aspect of the present invention, a synthetic strand product is provided. The synthetic strand product comprises the steps of withdrawing a plurality of glass fibers from the molten glass source, providing a supply of one or more second fibers of the second material, and applying the size of the aqueous base to the first fibers and the second fibers. And drying the size of the first fiber and the second fiber by contacting the sized first and second fibers with a heating member, and collecting the first and second fibers into synthetic strands. .

According to a fourth aspect of the present invention, an apparatus for producing a plurality of sized first fibers and second fibers is provided. The apparatus comprises a heating bushing for supplying a flow of molten glass to be drawn towards a continuous first fiber, a drawer suitable for drawing the flow towards the first fiber, and a feeder for supplying one or more second fibers of a second material And one or more applicators for applying the size to the first and second fibers. The apparatus may further comprise a drying apparatus for contacting and delivering energy in the form of heat to the first and second fibers sized to dry the size on the first and second fibrous fibers. The drying apparatus preferably includes a heating contact plate. Further, the takeout device may include a winding device or an in-line chopping device.

According to a fifth aspect of the present invention, a method of forming a plurality of sized first fibers and second fibers is provided. The apparatus includes drawing a plurality of first fibers from a molten glass source, providing a supply of one or more second fibers of a second material, applying a size to the first fibers and the second fibers, Mixing at least one first fiber and a second fiber with the first fiber. The second fiber is preferably selected from the group consisting of S-grass fibers, graphite fibers, and polymer fibers. More preferably, the second fiber is selected from the group consisting of polyamide fibers, polypropylene fibers and polyphenylene sulfide fibers.

In a preferred embodiment, the method further comprises contacting the sized first and second fibers with a heating element to dry the size of the first and second fibrous phases. The size of the aqueous base can be applied to the first and second fibers. In this case, the heating member may evaporate at least part of the water in the size of the aqueous base.

According to a sixth aspect of the present invention, an apparatus for producing one or more synthetic strands is provided. The apparatus comprises a heating bushing for supplying a flow of molten glass to be drawn towards a continuous first fiber, a drawer suitable for drawing the flow towards the first fiber, and a feeder for supplying one or more second fibers of a second material And an applicator for applying the size to the first and second fibers, a drying device for contacting and transferring thermal form energy to the one of the first and second fibers to dry the size on the fibers; And an apparatus for gathering the second fiber into one or more synthetic strands.

It is an object of the present invention to provide an improved in-line method of forming certain synthetic strand products. Another object of the present invention is to provide an improved apparatus for producing synthetic strand products. Another object of the present invention is to provide an improved synthetic strand product. Yet another object of the present invention is to provide an improved apparatus for producing a plurality of sized first and second fibers. It is still another object of the present invention to provide an improved method of forming a plurality of sized first and second fibers. These and other objects and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings and the appended claims.

BACKGROUND OF THE INVENTION Field of the Invention The present invention relates generally to the manufacture of synthetic materials, and more particularly to methods and apparatus for forming synthetic strands from materials such as glass fibers and organic fibers.

1 is a perspective view showing a composite strand forming apparatus constructed in accordance with a first embodiment of the present invention.

1A is a side view illustrating an in-line chopper.

FIG. 2 is a side view of the apparatus shown in FIG. 1. FIG.

FIG. 3 is a view taken along line 3-3 of FIG. 2.

4 is a side view showing a composite strand forming apparatus constructed in accordance with a second embodiment of the present invention.

Fig. 5 is a front view showing the composite strand forming apparatus constructed in accordance with the third embodiment of the present invention.

An apparatus for producing a synthetic strand product according to the present invention is shown in FIG. 1, usually indicated by reference numeral 10. The apparatus 10 includes a bushing 12 having a plurality of orifices (not shown) through which a plurality of molten glass flows are discharged. In the embodiment shown in FIG. 1, the flow of glass is mechanically discharged to form the first continuous fiber 14 and via the winder device 20. The glass fibers may be thinned with water using a prepad spray (not shown) located between the bushing 12 and the first applicator roller 30.

The first fiber 14 passes through a first applicator roller 30 in contact with the front, which applies a first liquid coating of the sizing composite (also referred to below as size / binder) to the fiber 14. . The sizing composite is typically an aqueous base, but may have other suitable other forms. When stretched to contain the sizing compound and rotated with a conventional drive 30a, the sizing compound is transferred from the bin 32 to the fibers 14. Other devices or techniques for applying the size to the glass fibers 14 may be used in place of the applicator roller 30.

In the described embodiment one or more packages 62 of two second material fibers 66 are supported on a package support rack 60. The second fiber 66 is extracted through the winder device 20 in the package 62 and in the described embodiment extends through four suitable multiple eye eyes 64 and contacts the back. It serves to position the second material fiber 66 in contact with the applicator roller 35 so as to control the point so that the fiber 66 engages the heating device 41 to be described later in more detail.

The second material fiber 66 is extracted from various kinds of composites. Preferably, the second material fiber 66 is extracted from the group consisting of S-glass fiber, graphite fiber, and polymer fiber, more preferably the second material fiber 66 is made of polyamide fiber, polypropylene fiber and It is extracted from the group consisting of polyphenylene sulfide fibers. It is also contemplated that inorganic or organic fibers not specifically described herein may be used.

A second applicator roller 35 in contact with the rear applies the second liquid coating of the sizing composite onto the second material fiber 66. The second sizing composite may be the same or different composite as the first sizing composite. The bin 36 containing the sizing compound is located below the roller 35. The roller 35 extends toward the bin 36 and, when rotated with the conventional drive 30a, transfers the sizing composite from the bin 36 to the second material fiber 66. Other devices or techniques for applying the size to the second material fiber 66 may be used in place of the applicator roller 35.

After the first fiber 14 has passed through the first applicator roller 30, it is filed on August 17, 1994, entitled “Continuous Glass Fiber Forming Method and Apparatus,” the disclosure of which is hereby incorporated by reference. And contact with a heating device 41 substantially similar to the heating device described in co-transferred and pending US patent application Ser. No. 08 / 291,801. 1 and 2, an engagement roller or bar 40 formed of a ceramic material is provided between the first applicator roller 30 and the heating device 41 so that the first fiber 14 is applied to the first applicator. It is brought into contact with both the roller 30 and the heating device 41.

The heating device 41 comprises a first plate 42 having a curved outer surface 42a which is in direct contact with the fiber 14, preferably in full length. The resistive heating second plate 44 connected to the power source 44a functions to radially heat the first plate 42 at a distance from the first plate 42. As the fiber 14 passes through the first plate 42, thermal energy is transferred from the first plate 42 to the sized fiber 14. When the size of the aqueous base is used, the heat transferred from the first plate 14 to the fibers 14 evaporates water at the size.

Preferably, the second material fiber 66 is in contact with the first plate 42 at a position below the midpoint of the plate 42 such that the fiber 66 contacts only about one third of the length of the plate 42. do. This means that excessive heating of the second fiber 66 is possible. The type of material used for the second material fiber 66 clearly determines the acceptable amount of heat exposure. In this state, "acceptable heat exposure" means the amount of thermal energy that can be applied to the second material fiber 66 before the physical properties change significantly. Thus, some fibers 66, such as various non-polymeric fibers, may be in contact with the plate 42 over one third or more of its length.

Referring to FIG. 2, the first plate 42 has a length L = 40.0 inches (1016 mm), a thickness T = 0.375 inches (9.525 mm), and a radius of curvature is 267 inches (6782 mm). The plate 42 is made of stainless steel or copper or the like. Preferably, plate 42 is maintained at a temperature between 1000 ° F (537 ° C) and 1500 ° F (816 ° C), preferably at 1200 ° F (649 ° C).

In accordance with one embodiment of the present invention, the size / binder is one or more binders such as water, film formers, silane binders commercially available in the OSI industry under the names A1100 and A1120, and under the name KESSCO BES. One or more lubricants, such as fatty acid esters commercially sold by the Stephan company, a mixture of acetic acid and stearic acid commercially available from Owens Corning Piebergers under the name K12, and under the name Polyemulsion 43N40. polypropylene waxes modified with maleic anhydride commercially available from of America, Aldrich Chemical Co. Terephthalic acid, commercially available from Lindau Chemical Inc. under the name Maldene 286. And modifiers such as partial ammonium salts of butadiene-maleic acid copolymers commercially available. Preferably, the film forming agent is vinyl acrylic commercially available from Franklin International under the product names Covinax 201 and Covinax 225 or under the name Synthemul 97903-00 under Riechold Chemicals Inc. Contains urethanes sold commercially. Epoxy, polyvinyl, and polyester can also be used as film forming agents in the present invention.

When the second fiber 66 is in contact with the first plate 42, they are mixed with the first fiber 14. After passing through the first plate 42, the first and second fibers 14, 66 gather through the gathering shoe 50 to form a single synthetic strand 16. The strand 16 in the gathering shoe 50 is wound up via a winder device 20, which is a Type-30 ^™ winder device in the described embodiment, over the sleeve or tube 90 shown in FIG. 2. The synthetic strand package 92 is formed. The winding device 20 also includes a conventional switching mechanism 24 that allows the strand 16 to form a square end package along the length of the tube 90. In addition, when the strands 16 strike, an air supply device 26 for outputting a plurality of air flows to be cooled before being wound is provided.

In an alternative embodiment, the single strand 16 has a Neumag USA Corp. name under the name of the NMC-1 cutter, as shown in FIG. 1A. Can be withdrawn in a conventional in-line chopper 55, which is one of commercially available products, and can be cut into separate pieces that can be collected in a container 57. Separation fragments may have a length ranging from about 1/16 (1.5875 mm) to 2 inches (50.8 mm).

In the process of the invention, the glass (first fiber) percent is about 30 to 70 weight percent, the second material (second fiber) percent is about 30 to 70 weight percent, and the binder / size percent is about 0 to 15 weight percent Phosphorous synthetic strands are prepared. However, the process can produce synthetic strands having about 5 to 90% by weight of the second material (second fiber).

2 and 3, the first and second plates 42, 44 are embedded in a cabinet 46, spaced and approached relative to the fibers 14. The cabinet 46 includes first and second doors 46a and 46b which function as heat shields when closed. The doors 46a and 46b are preferably formed of an insulating plate such as calcium silicate having a thickness of 1 inch (25.4 mm).

The reciprocating device 70 is provided to move the cabinet apart and approach the fiber 14. The device 70 comprises first and second connecting mechanisms 72a and 72b and a piston cylinder drive 74. The connecting mechanisms 72a and 72b are connected to the cabinet 46 and the support member 80. The piston-cylinder drive 74 is fixedly connected to one of the plurality of supports 76 extending from the support 80 and extending between the first and second connecting mechanisms 72a, 72b shown in FIG. do. The reciprocating motion of the piston 74a of the drive 74 performs the motion of the cabinet 46 and the motion of the first plate 42 therefrom.

In the first alternative embodiment shown in FIG. 4, the same reference numbers indicate the same elements, and a single applicator roller 130 is used to apply the sizing composite to the first and second fibers 14, 66. Let's do it. The bin 132 containing the sizing compound is located below the roller 130. In this embodiment, the second fiber 66 is fitted with the plate 42 after contacting the applicator roller 130 through the first positioning bar or roller 140 before weeding the applicator roller 130. Contact with the second positioning bar or roller 142 before contacting.

In the second alternative embodiment shown in FIG. 5, the applicator roller 130 and positioning bars 140, 142 are positioned as shown in FIG. 4 so that the first and second fibers 14, 66 are Pass the applicator roller 130. Separation shoes 50a are used to separate the second fibers 66 into the same number of first groups of fibers 14a having one or more second fibers 14. Each of the first fiber groups 14a is mixed with the second fiber group 66a to form a plurality of synthetic strands 16a spaced apart. The spaced strands 16a can be gathered into the gathering shoe 50 to form a single strand 160 combined and wound through the winder device 20 to form a package 160a. Optionally, one or more spaced strands 16a may be wound into two or more separate packages through two or more winding devices (not shown).

Synthetic strands formed according to the present invention can be cut into spaced fragments and used in injection molding methods. They are also mat thermoplastics (GMT), pultrusion, filament winding, knitting, weaving, extrusion coating, needling It can be used as a continuous synthetic strand by methods such as texturing, continuous fiber mat formation, and the like.

The apparatus and method of the present invention produce synthetic strands having many advantages in the light of the prior art. First, the method can produce a ternary, quaternary, or more complex synthetic strand. For example, the strand may include various kinds of glass such as E-grass and S2 glass, and may include various kinds of various organic materials such as polypropylene and polyphenylene sulfide. Second, the synthetic strands of the present invention show an improved degree of dispersion of the fibers in the final composite section. Third, it is believed that the binder / size of the present invention increases composite part properties such as tensile and impact strength. Relatively large amounts of binders in synthetic strands result in synthetic strand products that remain intact and are easily handled. Finally, various binders / sizes can be used and applied to the fibers dispersed by the separate applicator rollers.

Given the following detailed description of the invention with respect to the following examples, it will be understood that in some respects it is not to be taken as limiting the invention.

Example 1

The glass marble melts and draws 22 pounds per hour at a speed of 900 feet per minute (fpm) (4.572 m / s) through a bush with two thousand holes. The resulting fiber has a "M" (16 micron) filament diameter. The newly formed E-grass fibers are immediately cooled by prepad spraying of water. The fibers are then processed to the size formation of Example 5 via an applicator roller facing the front. The fibers are supported against the applicator surface by ceramic bars with slightly altered fiber orientation. 2520 (2.8 E-4 g / km) to 5040 deniers of 1260 deniers, commercially available from Dupont Chemical under the trade names "Nylon 66, 1400 decitex 11260 denir, 210 fil, R 20 Tt, Type 728". Two 15 pound (6.8 kg) packages (5.6 E-4 g / km). The packages are placed on a package feed rack located at the bushing height of the glass forming operation. Then, the two polymer fiber ends are applied to the second polymer fiber through the two ceramic guide eyes at the bushing height and through the two ceramic guide eyes installed directly on the second applicator roller that is in contact with the second polymer fiber. The glass is drawn out through a second applicator roller that is in contact with the back. The mixed polymer and glass fibers are heated to a temperature of about 1200 ° F. (649 ° C.) and dried on a 40 inch (1016 mm) hotplate wound on a rotating collet.

Example 2

Polypropylene fibers and glass fibers were mixed in the same manner as described in Example 1 except that the size formation of Example 7 was used. Polypropylene fibers of 2520 denier (2.8 E-4 g / km), commercially available from Amoco / Phillips under the name "MARVESS Olefin Filament Yarn and J01 Natural 2520 DEN-210-00", are each 5040 (5.6 E-). Two 15 pound (6.8 kg) packages ranging from 4 g / km) to 10080 deniers (11.2 E-4 g / km) are lobed in the separation operation. The packages are placed on a package feed rack located at the bushing height and two lobed polypropylene fibers are used to produce a polypropylene / glass mixed strand product.

Example 3

Polypropylene fibers and glass fibers were mixed in the same manner as described in Example 1 except that the size formation of Example 9 was used. 200 deniers (0.222 E-4 g / km) of polypropylene fibers, commercially available from Amoco / Phillips under the trade names "polypropylene sulfide-filament" or "staple CP-1-26G", are each 1000 (1.1 E). Two 15-pound (6.8 kg) packages of -4 g / km) are lobed for separation. The packages are placed on a package feed rack located at the bushing height and two lobed polypropylene fibers are used to produce a blended product.

Example 4

S2-grass is mixed with E-grass in the same manner as the polymer fibers are mixed with the E-grass fibers of Example 1. In this case, two S2-Glass packages commercially available from Owens Corning Fiberberger under the name "Product 449, Yield = 750" are placed on a package supply rack at bushing height. The two ends of the S2-grass are drawn towards the E-grass flow in the same way that the ends of the polyamide fibers are drawn towards the E-grass flow in Example 1. The sizing component described below in Example 9 is applied to S2-grass and E-grass. The loading of S2-grass is used to produce a final product in the range of 20-40% using the above method.

Example 5

Six thousand (6000) grams (g) of binder are formed in the following procedure. 15 g (0.25% bougebi on water) of A-1100 silane is added to 2345 g of deionized water. The silane is stirred for a few minutes. 1875 g (31.25%) of film former Covinax 201 and 1500 g (25.0%) of film former Covinax 205 are mixed in a 2 gallon (7.6 L) barrel. The silane solution is then shaken moderately and mixed with the mixture of film forming agents. 480 g (8.0%) of Maldene 286 is added to the mixture of silane and film former. Finally, 200 g (3.3%) of BES homogenate is added under continuous stirring. The solid concentration of the binder polymer solution thus produced is 30%. Referring to Example 1 above, this binder polymer solution is useful where the polyamide is mixed with the glass.

Example 6

Six thousand (6000) grams (g) of binder are formed in the following procedure. 15 g (0.25%) of A-1100 silane is added to 1870 g of deionized water. The silane is stirred for a few minutes. 3450 g (57.5%) of film forming agent Synthemul 97903-00 are mixed in a 2 gallon (7.6 L) barrel. The silane solution is then shaken moderately and mixed with the mixture of film forming agents. 480 g (8.0%) of Maldene 286 is added to the mixture of silane and film former. Finally, 200 g (3.3%) of BES homogenate is added under continuous stirring. The solid concentration of the binder polymer solution thus produced is 30%. The binder polymer solution is useful where the polypropylene is mixed with the glass.

Example 7

Six thousand (6000) grams (g) of binder are formed in the following procedure. 15 g (0.25%) of A-1100 silane is added to 2325 g of deionized water. The silane is stirred for a few minutes. 1875 g (31.25%) of film former Covinax 201 and 1500 g (25.0%) of film former Covinax 205 are mixed in a 2 gallon (7.6 L) barrel. The silane solution is then shaken moderately and mixed with the mixture of film forming agents. A terephthalic acid solution was prepared by decomposing 30 g (0.5%) of terephthalic acid in 30 ml of concentrated ammonium hydroxide. The terephthalic acid solution is added to the mixture of silane and film former. Then 300 g (5.0%) of polyemulsion 43N40 are added to the mixture. Finally, 200 g (3.3%) of BES homogenate is added under continuous stirring. The solid concentration of the binder polymer solution thus produced is 30%. The binder polymer solution is useful where the polypropylene is mixed with the glass.

Example 8

Six thousand (6000) grams (g) of binder are formed in the following procedure. 15 g (0.25%) of A-1100 silane is added to 2020 g of deionized water. The silane is stirred for a few minutes. 3450 g (57.5%) of film forming agent Synthemul 97903-00 are mixed in a 2 gallon (7.6 L) barrel. The silane solution is then shaken moderately and mixed with the film forming agent. A terephthalic acid solution is prepared by decomposing 30 g of terephthalic acid in 30 ml of concentrated ammonium hydroxide. Terephthalic acid solution is added to the mixture of silane and film former. Then 300 g (5.0%) of polyemulsion 43N40 are added to the mixture. Finally, 200 g (3.3%) of BES homogenate is added under continuous stirring. The solid concentration of the binder polymer solution thus produced is 30%. The binder polymer solution is useful where the polypropylene is mixed with the glass.

Example 9

Six thousand (6000) grams (g) of binder are formed in the following procedure. 15 g (0.25%) of A-1100 silane is added to 1870 g of deionized water. The silane is stirred for a few minutes. 3450 g (57.5%) of film forming agent Synthemul 97903-00 are mixed in a 2 gallon (7.6 L) barrel. The silane solution is then shaken moderately and mixed with the film forming agent. Finally, 200 g (3.3%) of BES homogenate is added under continuous stirring. The solid concentration of the binder polymer solution thus produced is 30%. The binder polymer solution is useful with various types, including polypropylene sulfide and inorganic fibers.

Example 10

Six thousand (6000) grams (g) of binder are formed in the following procedure. 15 g (0.25%) of A-1100 silane is added to 2345 g of deionized water. The silane is stirred for a few minutes. 1875 g (31.25%) of film-forming agent Covinax 201 and 1500 g (25.0%) of film-forming agent Covinax 205 are mixed in a 2 gallon (7.6 L) barrel. The silane solution is then shaken moderately and mixed with the mixture of film forming agents. Finally, 200 g (3.3%) of BES homogenate is added under continuous stirring. The solid concentration of the binder polymer solution thus produced is 30%. The binder polymer solution is useful with a variety of materials including polypropylene sulfides and inorganic fibers.

Although the invention and its preferred embodiments have been described in detail, it is obvious that modifications and variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims (29)

In at least one synthetic strand manufacturing apparatus, A heating bushing for supplying a flow of molten glass to be drawn toward the first continuous fiber; An extractor suitable for drawing the flow towards the first fiber; A feeder for supplying at least one second fiber of a second material; At least one applicator for applying a size to the first and second fibers, A drying device for contacting and delivering thermal energy to the first and second sized fibers to dry the size on the first and second fibers prior to gathering the first and second fibers on the one or more strands Wow, Apparatus for producing a composite strand comprising a device for gathering the first and second fibers into one or more synthetic strands. The composite strand manufacturing apparatus according to claim 1, wherein the drying apparatus includes a heating contact plate. 2. The gathering apparatus of claim 1, further comprising a gathering shoe positioned between the drying device and the take out device to gather the first and second fibers into one or more synthetic fibers. Synthetic strand production apparatus. The composite strand manufacturing apparatus according to claim 1, wherein the takeout apparatus further comprises a winding apparatus. 2. The apparatus of claim 1, wherein the drawer comprises an in-line chopping device. 2. Apparatus according to claim 1, wherein a single applicator is provided for applying the size to said first and second fibers. 2. Apparatus according to claim 1, wherein a first applicator is provided for applying the size to the first fiber and a second applicator is provided for applying the size to the second fiber. In at least one synthetic strand forming method, Withdrawing a plurality of glass first fibers from a molten glass source, Providing a supply of one or more second fibers of a second material; Applying a size to the first and second fibers, Contacting said sized first and second fibers with a heating member to dry said size on said first and second fibers, wherein said contacting said sized first and second fibers with said heating member Causing said coincidence to occur with said drawing of said first fiber; At least one composite strand, comprising gathering the first and second fibers into at least one composite strand. 9. The method of claim 8, wherein said second fiber is selected from the group consisting of S-grass fibers, graphite fibers, and polymer fibers. 9. The method of claim 8, wherein said second fiber is selected from the group consisting of polyamide fibers and polypropylene fibers. 10. The method of claim 8, wherein said size comprises a size of an aqueous base and said heating member evaporates at least a portion of the water within said size of said aqueous base. 12. The method of claim 11 wherein the size of the aqueous base comprises a film former consisting of an acrylic polymer emulsion. In synthetic strand products, Withdrawing a plurality of glass fibers from a molten glass source, Providing a supply of one or more second fibers of a second material; Applying a size of an aqueous base to the first and second fibers, Contacting the sized first and second fibers with a heating member to dry the size on the first and second fibers; And collecting the first and second fibers into synthetic strands. In the plurality of sized first fiber and second fiber manufacturing apparatus, A heating bushing for supplying a flow of molten glass to be drawn toward the first continuous fiber; An extractor suitable for drawing the flow towards the first fiber; A feeder for supplying at least one second fiber of a second material; At least one applicator for applying a size to the first and second fibers, And a drying apparatus for contacting and transferring the thermal energy to the first and second fibers sized to dry the sizes of the first and second fibrous fibers. 1 fiber and 2nd fiber manufacturing apparatus. 15. The apparatus of claim 14, wherein the drying apparatus comprises a heating contact plate. 15. The apparatus of claim 14, wherein the takeout device comprises a winding device. A method of forming a plurality of sized first fibers and a second fiber, Drawing the plurality of first fibers from the molten glass source, Providing a supply of one or more second fibers of a second material; Applying a size to the first and second fibers, Contacting said sized first and second fibers with a heating member to dry said size on said first and second fibers, wherein said contacting said sized first and second fibers with said heating member Causing said coincidence to occur with said drawing of said first fiber; And mixing said at least one second fiber with said first fiber. 18. The method of claim 17, wherein the at least one second fiber is selected from the group consisting of S-grass fiber, graphite fiber, and polymer fiber. 18. The method of claim 17, wherein the second fibers are selected from the group consisting of polyamide fibers and polypropylene fibers. 18. The plurality of sized first fibers of claim 17, wherein the size comprises a size of an aqueous base, and wherein the heating element comprises evaporating at least a portion of the water in the size of the aqueous base. Second fiber forming method. In at least one synthetic strand manufacturing apparatus, A heating bushing for supplying a flow of molten glass to be drawn toward the first continuous fiber; An extractor suitable for drawing the flow towards the first fiber; A feeder for supplying at least one second fiber of a second material; An applicator for applying a size to one of the first and second fibers, A drying apparatus for contacting and transferring thermal form energy to the one of the first and second fibers to dry the size on the fibers; At least one synthetic strand manufacturing device comprising gathering the first and second fibers into at least one synthetic strand. 9. The method of claim 8, wherein said heating member is secured during contact with said sized fibers. 18. The method of claim 17, wherein the heating member is secured during contact with the sized fibers. 9. The method of claim 8, wherein each of the at least one synthetic strand has the second fibers generally dispersed with the first fiber over a strand cross-sectional area. 18. The plurality of sized first and second fibers of claim 17, wherein each of the one or more synthetic strands has the second fibers generally dispersed with the first fiber over a strand cross-sectional area. Forming method. 9. The method of claim 8, wherein the heating element is maintained at a temperature between about 1000 and 1500 degrees F (between about 538 and 816 degrees C) to dry the size on the fibers. . 18. The plurality of sized articles of claim 17, wherein the heating element is maintained at a temperature between about 1000 and 1500 degrees F (between about 538 and 816 degrees C) to dry the size on the fibers. 1 fiber and a second fiber forming method. A method of forming a plurality of sized first fibers and a second fiber, Drawing the plurality of first fibers from the molten glass source, Providing a supply of one or more second fibers of a second material; Applying a size to the first and second fibers, Contacting the sized first and second fibers with a heating member to heat the size on the first and second fibers, wherein the contact of the sized first and second fibers with the heating member Causing said coincidence to occur with said drawing of said first fiber; And mixing said at least one second fiber with said first fiber. 29. The formed sized plurality of first and second fibers of claim 28, wherein the size comprises a size of an aqueous base and the heating member evaporates at least a portion of the water in the size of the aqueous base. Way.

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